Wheel assembly for a vacuum cleaner

ABSTRACT

A vacuum cleaner having a specific ratio of wheel diameter to wheel separation distance in addition to a u-shaped yoke operably coupled to an axle, thus giving the vacuum cleaner a zero turn radius allowing the user to more easily and efficiently operate and maneuver the vacuum cleaner. The vacuum cleaner may also include one or more vacuum cleaner components disposed between the wheels.

RELATED APPLICATIONS

Priority is hereby claimed to U.S. Provisional Application No. 61/418,726 filed on Dec. 1, 2010, the entire contents of which are hereby incorporated by reference.

BACKGROUND

The present invention relates to an upright vacuum cleaner and more particularly to an upright vacuum cleaner having a base assembly and an upper housing that are able to rotate with respect to one another.

SUMMARY

In one embodiment, the invention provides a vacuum cleaner having a first wheel and a second wheel set apart a wheel separation distance, where the first wheel and second wheel are capable of independent rotation. The vacuum cleaner also includes a cord reel disposed between the first wheel and second wheel and a suction nozzle having a width wherein the ratio of suction nozzle width to wheel separation distance is between 1.6 and 3.5.

In another embodiment the invention provides a vacuum cleaner having a housing, an axle coupled to the housing, and a first wheel having a diameter and operably coupled to the axle. The invention further has a second wheel set apart a wheel separation distance from the first wheel, the first wheel and second wheel being capable of independent rotation. In this invention the ratio of first wheel diameter to wheel separation distance is between 0.85 and 2.

In an alternative embodiment, the invention provides a vacuum cleaner having a first wheel and a second wheel set apart a wheel separation distance, the first wheel and second wheel being capable of independent rotation, and a housing disposed between the first wheel and second wheel, the housing being partially disposed in an interior portion of a base. The vacuum cleaner further provides the base having a suction nozzle wherein the suction nozzle has a nozzle width, the ratio of suction nozzle width to wheel separation distance being between 1.6 and 3.5.

Yet another alternative embodiment of the invention provides a vacuum cleaner having a first wheel and a second wheel, the first wheel and second wheel being disposed on an axle and being capable of independent rotation. The invention also provides an electrical cord for providing electrical power to the vacuum cleaner, the electrical cord having a stored position in which the cord is wrapped around the axle.

An alternative embodiment of the invention provides a vacuum cleaner having a base having a suction nozzle wherein the suction nozzle has a nozzle width, an upper housing having a motor, a dirt collection chamber and a yoke having an open interior portion, and a first wheel and a second wheel set apart a wheel separation distance, the first wheel and second wheel being disposed in the open interior portion of the yoke. The invention also includes a housing disposed in the open interior portion of the yoke, and an axle coupled to the base, the yoke, the first wheel, the second wheel and the housing.

Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a zero radius turn vacuum cleaner.

FIG. 2 is a perspective view of wheels and a cord reel of the zero radius turn vacuum cleaner of FIG. 1.

FIG. 3 is another perspective view of the wheels and the cord reel of the zero radius turn vacuum cleaner of FIG. 1.

FIG. 4 is a section view of the wheels and cord reel of the zero radius turn vacuum cleaner taken along line 4-4 of FIG. 1.

FIG. 5 is a section view of an alternative embodiment of the vacuum cleaner of FIG. 1 taken along line 4-4 of FIG. 1.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

A zero radius turn vacuum cleaner 10 is illustrated in FIG. 1 and includes a base assembly 12, a first wheel 14, a second wheel 16, a cord reel assembly 18, a dirty air hose 20 (illustrated in FIG. 3) and an upper housing 22. The embodiment illustrated in FIG. 1 shows the cord reel assembly 18 disposed between the first wheel 14 and second wheel 16, however, other embodiments have other vacuum cleaner components such as, by way of example only, a filter, a fan motor, one or more wheel driving motors or a dirt cup disposed between the first wheel 14 and the second wheel 16. Other alternative embodiments may include a combination of vacuum cleaner components, such as, by way of example only, the cord reel assembly and a filter, the cord reel assembly and a fan motor, etc., disposed between the first wheel 14 and the second wheel 16.

The base assembly 12 includes a suction nozzle 24 and an axle 26 (illustrated in FIG. 2). The base assembly is formed approximately in the shape of a “U”, with the suction nozzle 24 being disposed approximately at the base of the “U” and the axle 26 coupled between the arms of the “U”. The suction nozzle 24 has a width N (illustrated in FIG. 1) of approximately 14 inches. Other embodiments may have a width N between 12 and 16 inches. The base assembly includes a hose opening (not shown) to enable connection of the dirty air hose 20 to the base assembly 12. The suction nozzle 24 is fluidly connected to the hose opening. The base assembly 12 includes a first recess 28 disposed on one arm of the “U” and a second recess 30 on the other arm of the “U” to receive the axle 26. In one construction the base assembly 12 is made of multiple pieces which are coupled together using screws. In another construction the base assembly is a single piece.

The axle 26 is hollow and is made of plastic. In another construction, the axle 26 is made of metal such as steel or aluminum. In yet another construction, the axle 26 is solid. The axle 26 has two apertures 31 thereon to allow a wire or the like to enter and exit the interior portion of the axle 26. Alternative constructions may have additional apertures to allow for additional entry and exit points into the axle. Another alternative construction may include caps placed in each end of the axle 26 near the first and second recesses 28, 30 to seal the ends of the axle 26. Both ends of the axle 26 are received in the base assembly 12 such that that the axle 26 is coupled to the base assembly 12. The first and second recesses 28, 30 are sized to inhibit rotation of the axle 26 with respect to the base assembly 12. In some embodiments the axle 26 is coupled to the first and second recesses 28, 30 to inhibit rotation of the axle 26 with respect to the base assembly 12.

The upper housing 22 includes a handle 32, a dirt chamber 34, a motor housing 33 and a yoke 36. A dirt opening (not shown) is disposed on the dirt chamber 34 to allow the dirty air hose 20 to be fluidly coupled to the dirt chamber 34. A motor 54 for driving a suction fan (not shown) is disposed in the motor housing 33.

As shown in FIG. 4, the yoke 36 is in the shape of an inverted “U”, with the motor housing 33 being disposed at the base of the “U”. The yoke includes an open interior portion 37 illustrated in FIG. 1. The yoke 36 includes a first opening 38 and a second opening 40 to allow the axle 26 to pass through the yoke 36. Bearings 42 are disposed in the first and second openings 38, 40. The bearings 42 are sized and configured to allow the axle 26 to pass through the bearings 42. The bearings 42 allow the upper housing 22 to rotate with respect to the axle 26 and the base assembly 12.

The first wheel 14 and second wheel 16 are substantially similar. Both the first wheel 14 and the second wheel 16 have a width w of approximately 0.75 inches and a diameter d of 7.5 inches. Alternative embodiments may use a diameter d between 6.5 and 9 inches. Yet other alternative embodiments use a diameter d between 6.5 and 7.5 inches. The first and second wheels 14, 16 have openings 60, 62 disposed therein to allow the axle 26 to pass through the first and second wheels 14, 16. Bearings 39 are disposed in the openings 60, 62. The bearings 39 are sized and configured to allow the axle 26 to pass through the bearings 39. The bearings 39 allow the first wheel 14 and second wheel 16 to rotate with respect to the axle 26. The first wheel 14 and second wheel 16 may rotate independently of one another. One or more clips 43 are pressed on the axle 26 to inhibit movement of the first wheel 14 and the second wheel 16 along the rotational axis of the axle 26. The wheel separation distance D is defined as the distance between the centerline of the first wheel 14 and the centerline of the second wheel 16. In the illustrated embodiment, the first wheel 14 and the second wheel 16 have a wheel separation distance D of approximately 6 inches, but other embodiments envision placing the first wheel 14 and the second wheel 16 such that the wheel separation distance D is between 4.5 and 7.5 inches. In other embodiments the wheel separation distance D is 5.5 to 6 inches.

The ratio of first wheel 14 or second wheel 16 diameter d to wheel separation distance D to is important because the proper ratio assists in allowing the vacuum cleaner 10 to be easily maneuvered in tight spaces and assists in allowing the vacuum cleaner to have a zero turn radius. In the illustrated embodiment the ratio of wheel diameter d to wheel separation distance D to is 1.25. Alternative embodiments contemplate the ratio of wheel diameter d to wheel separation distance D being between 0.85 and 2. Yet other embodiments contemplate the ratio of wheel diameter d to wheel separation distance D being between 1.15 and 1.35. The zero turn radius allows the vacuum cleaner 10 to rotate about a central axis of the upper housing 22 while the first wheel 14 and second wheel 16 have minimal or no skid or slip with respect to a surface to be vacuumed. Prior art vacuum cleaners are not as easily maneuverable and do not have such a zero turn radius, at least in part due to their ratio of wheel diameter to wheel separation distance. It has been found that a vacuum cleaner 10 having a zero turn radius is easier to operate and use, as compared to vacuum cleaners not having a zero turn radius, thus leading to greater ease and efficiency in vacuuming.

The cord reel assembly 18, illustrated in section view in FIG. 4, includes a reel housing 44, a drum 46, a torsion spring 56, a brake (not shown), a brake release lever 47 (seen in FIG. 3), an electrical cord 48, a pair of commutator rings (not shown), and an electrical lead 50. The brake serves to inhibit drum 46 from rotating in at least one direction with respect to the reel housing 44. The reel housing 44 is cylindrical in shape and is hollow so that other elements of the cord reel assembly 18 may reside therein. The reel housing 44 has an opening 45 disposed thereon (seen in FIG. 3) to allow a portion of the electrical cord 48 to exit the reel housing 44. The drum 46 is disposed within the reel housing 44 and is able to rotate with respect to the reel housing 44. The reel housing 44 has an aperture 35 in the interior portion which is aligned with the aperture 31 of the axle 26 to allow the electrical lead 50 to exit the reel housing 44 and enter the axle 26. The electrical cord 48 is configured to provide electrical power to the vacuum cleaner 10.

The torsion spring 56 is disposed next to the drum 46 and is coupled to the drum 46 and the reel housing 44. The brake is coupled to the drum 46 and the reel housing 44. The brake is coupled to the brake release lever 47 such that when the brake release lever 47 is pressed, the brake is released. The brake release lever 47 is sized and configured such that it is easily operated with the user's foot. The reel housing 44 is coupled to the axle 26 by a key 49, to inhibit rotation of the reel housing with respect to the axle 26. In the illustrated embodiment the key 49 is an integral part of the reel housing 44, and the key 49 resides in a slot in the axle 26. In another construction, the key not an integral part of the reel housing 44. Alternative constructions may couple the reel housing 44 to the axle 26 with a friction fit, an adhesive, etc.

The electrical cord 48 may be substantially wound around the drum 46, but may be partially pulled out of the reel housing 44. The electrical cord 48 includes a plug 52 which, due to the size and configuration of the opening 45, is inhibited from entering the interior portion of the reel housing 44. The electrical cord 48 is electrically coupled to the pair of commutator rings. The commutator rings are electrically coupled to the electrical lead 50. The electrical lead 50 is electrically connected to the motor 54. As can be seen in FIG. 4, the electrical lead 50 exits the reel housing 44 through the aperture 35 and enters the interior portion of the axle 26 through the aperture 31. The electrical lead 50 then exits the interior portion of the axle 26 between the first wheel 14 and the yoke 36. The electrical lead 50 then enters the motor housing 33 where it is electrically connected to the motor 54. Thus when the electrical cord 48 is electrically connected to an electrical outlet, the motor 54 is able to receive electrical power. In an alternative embodiment the electrical lead 50 may also be electrically connected to another motor, a light, or some other accessory that requires electrical power.

In a stored position, the electrical cord 48 is substantially disposed in the interior of the reel housing 44, the electrical cord 48 being wrapped around the axle 26 as shown in FIG. 4. When the user pulls on the electrical cord 48 to extract a portion of the electrical cord 48 from the reel housing 44, the drum 46 rotates with respect to the reel housing 44. As the drum 46 rotates the torsion spring 56 is wound. The brake allows the drum 46 to rotate with respect to the reel housing 44, by means of a ratchet mechanism for example, in only one direction when the brake is applied. When the user wishes to wind the electrical cord 48 into the reel housing 44, the user pushes the brake release lever 47. When the brake release lever 47 is pressed, the brake is released which allows the drum 46 to rotate in either direction. The torsion spring 56 exerts a force on the drum 46 to turn the drum 46 in a direction that winds the electrical cord 48 back around the drum 46.

An alternative embodiment, illustrated in FIG. 5, of the vacuum cleaner 10 includes an independent drive motor 58 for the first wheel 14 and a second independent drive motor 58 for the second wheel 16. The independent drive motors 58 may take the form of pancake motors placed next to the wheels 14, 16. Thus each wheel 14, 16 can be driven independently of the other wheel 14, 16. In an alternative construction, drive motors can be placed between the wheels in place of the cord reel assembly 18. In yet another construction, a single drive motor with a transmission for each wheel can be placed between the wheels in place of the cord reel assembly 18. In yet other embodiments, each of the wheels can be driven in forward and reverse directions allowing for zero radius turns. The independent drive motors 58 are electrically connected to the electrical cord 48 in a similar fashion as has been described with regard to the motor 54. In yet another alternative embodiment the independent drive motors 58 can be used with the cord reel assembly 18, the independent drive motors 58 being disposed proximate to the cord reel assembly 18.

Yet another embodiment of the vacuum cleaner 10 has a filter housing and a filter, such as a HEPA filter, disposed between the wheels in place of the cord reel assembly 18. In this construction, conduits are coupled to the filter housing to deliver an air stream to and away from the filter. In yet another alternative embodiment a filter housing and filter are used in combination with the cord reel assembly 18, the filter housing and filter being disposed in an interior portion of the drum 44.

In the embodiment illustrated in FIGS. 1-4, only one axle 26 is used. However, other embodiments contemplate using multiple axles. Some constructions which are contemplated include an axle for the first wheel 14, an axle for the second wheel 16, an axle for the cord reel assembly 18, an axle for the yoke 36, and an axle for the base assembly 12, or any combination of these axles. In one construction, at least one of the axles may be offset from the other axles.

It has been found that placing the first wheel 14 and the second wheel 16 in the interior of the yoke 36 facilitates stable turns and allows the user to easily maneuver the vacuum cleaner 10 in small areas. The connection of the yoke 36 to the axle 26 also facilitates stable turns of the vacuum cleaner 10 and assists in allowing the user to easily maneuver the vacuum cleaner 10 in small areas. In fact, the location of the first wheel 14 and second wheel 16 with respect to the yoke, and the connection of the yoke 36 to the axle 26 allows the vacuum cleaner 10 to have a zero turn radius such that the vacuum cleaner 10 rotates about a central axis of the upper housing 22 while the first wheel 14 and second wheel 16 have minimal or no skid or slip with respect to a surface to be vacuumed. Prior art vacuum cleaners are not as easily maneuverable and do not have such a zero turn radius due to at least one of the location of their wheels and the connection of an axle to the housing instead of a yoke.

It has also been found that the ratio of suction nozzle 24 width N to wheel separation distance D aids in the stability of the vacuum cleaner 10 and assists in allowing the vacuum cleaner 10 in maneuvering in tight spaces. In the embodiment illustrated in FIGS. 1-4, the suction nozzle 24 width N to wheel separation distance D ratio is 2.3. However, other embodiments may have a suction nozzle 24 width N to wheel separation distance D ratio of between 2.0 and 2.5. Even other embodiments may have a suction nozzle 24 width N to wheel separation distance D ratio of between 1.6 and 3.5. In addition, the diameter d of the first wheel 14 and second wheel 16 aids in the stability of the vacuum cleaner 10 and assists in allowing the vacuum cleaner 10 in maneuvering in tight spaces.

Thus, the invention provides, among other things, a vacuum cleaner 10. Various features and advantages of the invention are set forth in the following claims. What is claimed is: 

1. A vacuum cleaner comprising: a housing; an axle coupled to the housing; a first wheel having a diameter and operably coupled to the axle; a second wheel set apart a wheel separation distance from the first wheel, the first wheel and second wheel being capable of independent rotation, wherein the ratio of first wheel diameter to wheel separation distance is between 0.85 and
 2. 2. The vacuum cleaner of claim 1 wherein the ratio of first wheel diameter to wheel separation distance is between 1.15 and 1.35.
 3. The vacuum cleaner of claim 2 further comprising: a drum coupled to the axle; and an electrical cord coupled to the drum.
 4. The vacuum cleaner of claim 3 further comprising a spring coupled to the drum for providing a force causing the drum to rotate.
 4. The vacuum cleaner of claim 1 wherein the first wheel and the second wheel are coupled to the axle.
 5. The vacuum cleaner of claim 4 further comprising a base having a suction nozzle, said base coupled to the axle.
 6. The vacuum cleaner of claim 1 wherein a motor is disposed in the housing.
 7. The vacuum cleaner of claim 6 wherein the motor powers a fan.
 8. The vacuum cleaner of claim 1 further comprising a motor coupled to the axle wherein the motor selectively drives the first wheel.
 9. The vacuum cleaner of claim 8 wherein the motor is a pancake motor.
 10. The vacuum cleaner of claim 1 further comprising: a drum coupled to the axle; a filter disposed in the interior of the drum.
 11. A vacuum cleaner comprising: a first wheel having a diameter and a second wheel, the first wheel and second wheel being disposed on an axle and being capable of independent rotation; an electrical cord for providing electrical power to the vacuum cleaner, the electrical cord having a stored position in which the cord is wrapped around the axle.
 12. The vacuum cleaner of claim 11 further comprising: an upper housing; a motor disposed in the upper housing; and an electrical lead electrically coupled to the motor and the electrical cord, wherein the electrical lead passes through at least one aperture in the axle.
 13. The vacuum cleaner of claim 12 further comprising: a drum for storing the electrical cord; and a spring coupled to a drum for providing a force causing the drum to rotate causing the electrical cord to be wrapped around the axle.
 14. The vacuum cleaner of claim 13 wherein the second wheel is set apart a wheel separation distance from the first wheel and further wherein the ratio of first wheel diameter to wheel separation distance is between 1.15 and 1.35.
 15. The vacuum cleaner of claim 11 wherein the second wheel is set apart a wheel separation distance from the first wheel and further wherein the ratio of first wheel diameter to wheel separation distance is between 0.85 and
 2. 16. A vacuum cleaner comprising: a base having a suction nozzle wherein the suction nozzle has a nozzle width; an upper housing having a motor, a dirt collection chamber and a yoke having an open interior portion; a first wheel having a diameter and a second wheel set apart a wheel separation distance from the first wheel, the first wheel and second wheel being disposed in the open interior portion of the yoke; a housing disposed in the open interior portion of the yoke; and an axle coupled to the base, the yoke, the first wheel, the second wheel and the housing.
 17. The vacuum cleaner of claim 16 further comprising an electrical cord having a stored position, wherein the electrical cord is wrapped around the axle in the stored position.
 18. The vacuum cleaner of claim 17 further comprising an electrical lead 50 electrically coupled to the motor and the electrical cord, wherein the electrical lead passes through at least one aperture in the axle.
 19. The vacuum cleaner of claim 18 wherein the ratio of first wheel diameter to wheel separation distance is between 1.15 and 1.35.
 20. The vacuum cleaner of claim 16 wherein the ratio of first wheel diameter to wheel separation distance is between 0.85 and
 2. 